Product package and related method

ABSTRACT

A package has a tray slidably mounted in a carton that has a opening bordered by a number of flaps. One or more stops on the tray are positioned to engage at least one of the flaps in order to restrict outward movement of the tray The tray can be positioned with a stop located inwardly of, and locked in place by, one or more of the flaps. By depressing one or more of the flaps the previously locked stop will be cleared and allowed to move outwardly past the flaps.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional PatentApplication, Ser No. 61/928,578, filed 17 Jan., 2014, the contents ofwhich are hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a paper board folding carton with aplastic tray insert is provided as a multi-use system to deliver aproduct to the consumer and be reused once opened. Alternatively thearrangement may be operated multiple times before it has a structuralfailure.

2. Description of Related Art

Existing prior art solutions typically entail rigid plastics at highvolumes and costly tooling, more robust outer cartons at higher costswith less esthetics regarding the finished unit, and such designs alsohave a higher degree of environmental impact to manufacture and disposeof during its life cycle.

SUMMARY OF THE INVENTION

In accordance with the illustrative embodiments demonstrating featuresand advantages of the present invention, there is provided a packageincluding a carton having an opening and one or more flaps around theopening. The package also includes a tray slidably mounted in the cartonand having one or more stops positioned to engage the one or more flapsin order to restrict outward movement of the tray.

In accordance with another aspect of the invention, a method is providedthat employs a tray slidably mounted in a carton that has an openingbordered by one or more flaps. The tray has at least one stop. Themethod includes the step of positioning the tray with the at least onestop located inwardly of, and locked in place by, the one or more flaps.Another step is depressing at least one of the one or more flaps toclear the at least one stop and allow movement of the at least one stopoutwardly past the one or more flaps.

The present arrangement provides a product package that integrates afirst thermoformed tray, with an optional thermoform lid, with a secondcomponent, namely a paper board carton that transforms the package froma single use container to a multi-use system that can be opened andclosed over a hundred times.

One exemplary feature of the present design is the integration betweenthe plastic articles and paper board carton. Using four flaps on one endof a standard folding carton, they are folded into the cardboard cartonto generate recoil energy in the paper board to spring out engaging theinner thermoformed part, in conjunction with a number of recessedsurfaces or bosses on the plastic articles. The package can be keptclosed until the consumer initiates the opening the unit.

Such an arrangement also maintains a similar relationship when opened,with additional surfaces keeping the plastic articles from beingseparated from the outer paper board carton, keeping the unit intact.

Once the unit is opened, a user now has access to the product orproducts by removing the product from the thermoformed package or fromopening the hinged lid of the inner plastic article. After use of theproduct the user returns the products to the container, closes the unit,and stores in the “Stiletto Pak” until they need to use again. Thisdesign uses a two piece inner plastic articles but can also be done witha single inner tray.

BRIEF DESCRIPTION OF THE DRAWINGS

The above brief description as well as other objects, features andadvantages of the present invention, including the package's shape,design and operation, will be more fully appreciated by reference to thefollowing detailed description of illustrative embodiments in accordancewith the present invention when taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 shows a package with a single piece thermoformed plastic insertwithin a folded cardboard sleeve having four folded end tabs accordingto one embodiment.

FIG. 2 shows several cutaway views of the package with a single piecethermoformed plastic insert within a folded cardboard sleeve having fourfolded end tabs according to one embodiment

FIG. 3 shows several perspective and cutaway views of the package with asingle piece thermoformed plastic insert within a folded cardboardsleeve having four folded end tabs illustrating the function of thefolded tabs according to one embodiment.

FIG. 4 shows several views of a hinged two piece thermoformed plasticinsert according to one embodiment.

FIG. 5 shows several perspective and cutaway views of the package withthe hinged two piece thermoformed plastic insert within a foldedcardboard sleeve having four folded end tabs illustrating the functionof the folded tabs according to one embodiment.

FIG. 6 shows several cutaway views of the package with the hinged twopiece thermoformed plastic insert within a folded cardboard sleevehaving four folded end tabs according to one embodiment

FIG. 7 shows several views of hinged two piece thermoformed plasticinsert according to one embodiment.

FIG. 8 shows several views of a two piece thermoformed plastic insertaccording to one embodiment.

FIG. 9 shows several views of the hinged lid for the two piecethermoformed plastic insert according to one embodiment.

DETAILED DESCRIPTION (Stiletto Pack)

Referring to FIGS. 1-3, the illustrated package has a tray 10 that isslidably mounted in carton 12 Four flaps 14 border an opening in carton12 (an upper flap, lower flap, and two side flaps). Tray 10 has areceptacle for receiving a product such as an e-cigarette. The forwardend of tray 10 has a flange-like, lower finger tab 10A. The back end oftray 10 is enlarged and forms a stop shown as aft abutments 16 and 17.

Tray 10 may be blow molded and has a well that forms a stop 18 (alsoreferred to as a forward abutment)

After loading product into tray 10, flaps 14 are folded inwardly beforesliding tray 10 into carton 12. Eventually, stop 18 will move inwardlypast lower flap 14, which flap will then lift and lock stop 18 inposition as shown in FIG. 2

To release tray 10, a user will squeeze and slightly rotate tab 10A downagainst package 12 to depress lower flap 14, thereby allowing stop 18 toclear the flap The user will then use tab 10A to slide tray 10 outwardlyinto the dispensing position shown in FIG. 3.

Outward movement of tray 10 will be halted when stops 16 and 17 engagethe side and upper flaps 14, respectively. The product can then beremoved from tray 10, used, and then returned to the tray.

Tray 10 can then be pushed back inside carton 12 until stop 18 passeslower flap 14 to lock the tray in place again.

Referring to FIGS. 4-9, the illustrated package has a tray 30 slidablymounted inside carton 32. Four flaps 34 border an opening in carton 32.Lid 31 snaps onto tray 30 and has a forward hinged section that canswing up as shown in FIG. 4 to allow access to the product (not shown)in tray 30. The forward end of lid 31 has a finger tab 31A. The back endof tray 30 has a pair of ribs 36 acting as stops (also referred to asaft abutments).

Tray 30 may be blow molded with a floor having a forward plateauadjacent a well that forms a stop 38 (also referred to as a forwardabutment)

After loading product into tray 30, flaps 34 are folded inwardly beforesliding the tray into carton 32. Eventually, stop 38 will move inwardlypast lower flap 34, which flap will then lift and lock stop 38 inposition as shown in FIG. 6. It will be noticed that lower flap 34 isaccessible at this time

To release tray 30, a user will squeeze lower flap 34 down againstpackage 32 to depress that flap, thereby allowing stop 38 to clear theflap. The user will then grasp tab 31A through notch 32A in package 32and pull tray 10 into the dispensing position shown in FIG. 4. Becausetwo separate hand movements are required for this maneuver, thispackaging is considered child resistant.

Outward movement of tray 30 will be halted when stops 36 engage the sideflaps 34. The product can then be removed from tray 30 by lifting lid31.

After closing lid 31, tray 30 can then be pushed back inside carton 32until stop 38 passes lower flap 34 to lock the tray in place again.

While only certain features of the invention have been illustrated anddescribed herein, many modifications, substitutions, changes orequivalents will now occur to those skilled in the art. It is therefore,to be understood that this application is intended to cover all suchmodifications and changes that fall within the true spirit of theinvention.

1. A package comprising: a carton having an opening and one or moreflaps around said opening; and a tray slidably mounted in said cartonand having one or more stops positioned to engage said one or more flapsin order to restrict outward movement of said tray.
 2. A packageaccording to claim 1 wherein at least one of said one or more flaps ismanually depressible to clear said at least one stop and increaseoutward mobility of said tray.
 3. A package according to claim 1 whereinsaid one or more stops comprise a forward abutment and an aft abutment,at least one of said one or more flaps being manually deflectable toclear said forward abutment and enable outward movement of said trayuntil said aft abutment engages at least one of said one or more flaps.4. A packaging method employing a tray slidably mounted in a carton thathas an opening bordered by one or more flaps, the tray having at leastone stop, the method comprising the steps of positioning the tray withsaid at least one stop being located inwardly of, and locked in placeby, said one or more flaps, and depressing at least one of said one ormore flaps to clear said at least one stop and allow movement of said atleast one stop outwardly past said one or more flaps.
 5. A packagingmethod according to claim 4 wherein said at least one stop comprises aforward and an aft abutment, the method comprising the step of: pullingsaid forward abutment outwardly past said one or more flaps until saidaft abutment engages at least one of said one or more flaps.